Aug'2021

Welcome to The IUP Journal of Mechanical Engineering

Focus

Computer-aided casting solidification process would help the industries to better understand the mold filling and temperature history of the solidifying castings. The process would help in identifying the defects with the aid of obtained time-temperature contours and optimizing the design parameters. Solidification plots, in a few cases, are found to show that at some locations of casting, temperature gradient becomes too high, which is perhaps the potential cause of porosity and shrinkage at that location. In the paper, "Optimization of Risering System and Its Experimental Validation Using Casting Simulation", the authors, Yadav Pranav M, Kumbhar Rushikesh B, Patil Akshaykumar S, Khatavkar Swarup V and Bhushan S Kamble, have used a freeware virtual simulation software and obtained various simulation results for 12 combinations of T-section component of aluminum metal. The results were compared with the casted specimens which are sliced at a vertical plane for observing the internal shrinkage defect, if any. An appropriate riser design is suggested by the authors from a comparison of analytical and experimental results.

Furan-No-Bake (FNB) sand mold system is a technology in high demand due to its good surface finish, dimensional stability and shake-out characteristics. Like any other system, FNB casting process is also not devoid of defects occurring due to the limitations of the process. There have been many instances where an apparently good casting has failed, only to reveal quite massive internal faults. Till recently, casting defects are analyzed by tools like DOE, If-Then rules, Ishikawa Charts, etc. The casting data analyzed are applied in certain optimization tools like ANOVA or Taguchi method. With the emergence of Genetic Algorithm (GA) and Artificial Neural Network (ANN), the concept of simulation has emerged as tools for simulation, which saves time and money. In order to optimize the FNB casting process parameters for minimum sand inclusion defect, in the second paper, "Application of Artificial Neural Network and Genetic Algorithm to Evaluate the Quality of Furan No-Bake Casting", the authors, Manojkumar V Sheladiya, Shailee G Acharya and Ghanshyam D Acharya, have generated the data randomly by providing a higher limit and lower limit of the process parameters. From the validation of output given by both methods, the authors have concluded that minimization of FNB sand inclusion defects is possible with the help of GA and ANN.

Metal Matrix Composites (MMCs) are the most sought-after materials in the field of aerospace, automobiles, turbines, etc. They received more attention for their lightweight, higher strength and stability than several other composites. The strength properties can further be improved by adding suitable fillers. Particulate reinforcement is one of the methods to enhance the strength, ductility and toughness of the composites. Stir casting technique was used to fabricate the MMC. In recent years, much work is being done on MMCs with graphite reinforcements, which exhibit low friction and wear rate and excellent mechanical properties. In the paper, "An Investigation of Mechanical Properties of Al6061/Graphite MMC Fabricated by Stir Casting Method", the authors, Vishwanath V H and Gururaj Hatti, have used 1%, 3% and 5% graphite reinforcement and studied the variations in the tensile strength, microhardness and microstructure. The study noted that an increase in graphite content has resulted in significant increase in the tensile strength and a decrease in hardness. The microstructures of the composites differ only in the degree of reinforcing particulates clustering. Thus, it is necessary to have a compromising percentage of graphite particulate to enhance the strength parameters without sacrificing on the hardness.

With the rapid industrialization of the workforce in the 21st century, many employees are exposed to mechanical vibration. Whole-Body Vibration (WBV) exposure can result in several health risks. Understanding how the body responds to vibration under different working conditions can throw light on the effective strategies to reduce the health risks. Since the human body displays anisotropic properties, i.e., the body displays different mechanical properties in response to different load orientations, when the whole body is exposed to vertical vibration, the body's asymmetric shape affects the response to translational and rotational motion due to seat-to-head transmissibility. In the last paper, "Biodynamic Response of Human Subjects Exposed to Whole Body Vibration in Forging", the authors, Kamaljeet Bhambri, Ishbir Singh, Harwinder Singh and Tejeet Singh, have presented the investigations on WBV exposures and transmissibility at head and back among Indian forging subjects. They note that more than 90% of industrial workers were affected due to high exposure of WBV with discomfort and stomach problems. Their study found that the dominant frequencies for 7-12 Hz and for 8-10 Hz would cause discomfort for different parts of human body.

S V Srirama Rao
Consulting Editor

Article   Price (₹)
Optimization of Risering System and Its Experimental Validation Using Casting Simulation
100
Application of Artificial Neural Network and Genetic Algorithm to Evaluate the Quality of Furan No-Bake Casting
100
An Investigation of Mechanical Properties of Al6061/Graphite MMC Fabricated by Stir Casting Method
100
Biodynamic Response of Human Subjects Exposed to Whole Body Vibration in Forging
100
Contents : (Aug' 2021)

Optimization of Risering System and Its Experimental Validation Using Casting Simulation
Yadav Pranav M, Kumbhar Rushikesh B, Patil Akshaykumar S, Khatavkar Swarup V and Bhushan S Kamble

In the metal casting process, higher yield and minimum defects level are expected by the foundry industries. In the present global and competitive world, metal casting industries need to perform efficiently with a reduction in rejections. The primary goal is to cast a defect-free component, and the secondary goal is to maximize the yield of casting by designing gating system and to find out optimum shape and sizes of feeders/risers, ingates, gates, etc. For obtaining better results, lots of time, the number of iterations and trial-and-error are required on the shop floor for experimentation. Virtually simulated casting trials make certain that actual castings are defect-free at first time and every time then after within a shorter lead time. Casting simulation provides reliable prediction of defects and good results even for complex-shaped castings. In this paper, the primary goal is to minimize the shrinkage defect by designing the appropriate-sized gating system for T section-shaped casting in considering riser dimensions like height and diameter and also maximize the yield of casting component using virtual simulation technique.


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Article Price : Rs.100

Application of Artificial Neural Network and Genetic Algorithm to Evaluate the Quality of Furan No-Bake Casting
Manojkumar V Sheladiya, Shailee G Acharya and Ghanshyam D Acharya

Defects occurring in any process are the ultimate limitations of the process. Furan No-Bake (FNB) casting process also faces the same problem. To find and minimize the conditions for acquiring least casting defects is very critical. Trial-and-error method was the normal method for minimizing defects. But due to disadvantages like being expensive, time-consuming and even prone results, this method costs too much to the industry. The goal of the company is optimum usage of resources to improve productivity of the organization. In this paper, genetic algorithm and artificial neural network have been used and applied to minimize the FNB casting defects for optimizing the process parameters of FNB casting process. The process parameters are selected on the basis of rigorous research, data collection and survey from different industries. The highest and lowest values of different process parameters were collected from the industry. On the basis of defect analysis, the dominant defect needs immediate attention for its minimization is 'Sand Inclusion'.


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Article Price : Rs.100

An Investigation of Mechanical Properties of Al6061/Graphite MMC Fabricated by Stir Casting Method
Vishwanath V H and Gururaj Hatti

Real utilization of aluminum and its combinations in aviation and car application prompted the modernization of a material as far as the alloying properties are concerned. Metal Matrix Composites (MMCs) are one of the vital advancements in the improvement of cutting-edge materials. Among the different lattice materials accessible, aluminum and its composites are generally utilized in the manufacture of MMCs in order to achieve modern generation materials. The accentuation has been given on creating moderate Al-based MMCs with different hard and delicate fortifications (SiC, Al2O3, zircon, graphite and mica) due to the likely potential outcomes of these blends in framing profoundly attractive composites. In the paper, the Al-Gr composite is produced using stir casting method. The composites prepared have different percentages of graphite. Mechanical properties like tensile and microhardness of the composites are investigated. Characterization of composite is done using Scanning Electron Microscope (SEM).


© 2021 IUP. All Rights Reserved.

Article Price : Rs.100

Biodynamic Response of Human Subjects Exposed to Whole Body Vibration in Forging
Kamaljeet Bhambri, Ishbir Singh, Harwinder Singh and Tejeet Singh

The paper presents the details of investigation of the Whole Body Vibration (WBV) among drop forging subjects. An input parameter of 1440 rpm was considered for conducting drawing operation to record the Vibration Dose Value (VDV) along x-axis, y-axis and z-axis. The values indicate that the average value of 20.11 2.13 ms-1.75 and the 8-hour equivalent vibration exposure [A(8) response] were beyond the ISO: 2631-1 (1997) recommended values. The study found that dominant frequencies for 7-12 Hz and for 8-10 Hz would cause discomfort for different parts of human body because of existing natural frequencies of human body. The results show that these dominant frequencies could cause discomfort, chest and abdomen pain and muscle disorder among subjects. It is concluded that the subjects required better environment in order to overcome WBV exposure.


© 2021 IUP. All Rights Reserved.

Article Price : Rs.100